[0001] The present invention relates to means for maintaining the sterility of a packaging
line during start-up or web transfer, and more particularly, to means in the form
of a package or kit for providing a sterilized splice between an expiring web of sterile
tubing and a new web of sterile tubing, or between a sterilizing boot and a web of
sterile tubing at start-up.
[0002] U.S. Patent No. 4,021,283, issued May 3, 1977, discloses a method of making aseptic
packaging. As disclosed in this patent a continuous, blown film tube of plastic material
is formed under aseptic conditions, flattened, and thereafter provided with a series
of regularly spaced transverse seals which extend from one edge of the flattened tube
to a point short of the opposite edge to form a channel along that edge to receive
a filling nozzle. By sterilizing the filling nozzle prior to its insertion in the
web of tubing, and also sterilizing the product to be packaged, aseptic conditions
are maintained within the bags, which are thereafter filled and sealed without being
opened to the atmosphere. In the case of food products, for example, this provides
a greatly increased shelf life.
[0003] U.S. Patent No. 4,171,604, issued October 23, 1979, is directed to a method for maintaining
the asepsis of a web of bags such as that shown in U.S. Patent No. 4,021,283 during
start-up and transfer from one web of bags to another. In accordance with the method
disclosed in U.S. Patent No. 4,171,604, a flexible boot is attached about the filling
nozzle prior to commencement of the packaging operation and the nozzle is thoroughly
sterilized by the introduction of steam or some other sterilizing agent into the boot.
After the nozzle has been sterilized an absorbant pad is positioned between a surface
of the boot and an opposing surface of the leading end of a web of packaging material
to sterilize these opposing surfaces. The nozzle is provided with a special fitting
which then allows the nozzle to pierce through the opposing surfaces of the boot and
the leading end of the web of bags. This permits the nozzle to be introduced into
the web of bags under aseptic conditions.
[0004] When the initial-web of bags is expended a new web of bags is brought into the packaging
machine in a similar manner. Thus, a pad of absorbant material containing a sterilizing
medium such as hydrogen peroxide is interposed between the opposing surfaces of the
trailing end of the expiring web of bags and the leading end of the new web of bags,
and once again using the special attachment on the filling nozzle, a hole is punctured
through. the opposing surfaces of the two webs of bags, allowing the nozzle to pass
under aseptic conditions from the old web into the new one.
[0005] While the system described above maintains the sterility of a web of bags as it is
introduced into the filling line, it will be apparent that the individual fabrication
and application of a pad of absorbant material each time a start-up or transfer is
made and the use of a special piercing nozzle assembly can be both time consuming
and expensive.
[0006] It is an object of the present invention to provide a package for, and a method of,
maintaining the sterility of a web of bags as it is fed into the filling system, both
at start-up and during the transfer from an expiring web of bags to a new. web of
bags, and without the necessity of a special piercing nozzle.
[0007] According to one aspect of the present invention there is provided a package for
maintaining the sterility of new and expiring webs of tubular material having sterile
interiors while transferring a filling nozzle from said expiring to said new web,
characterised by:
an inner sheet adapted to contact and sterilize opposed inner surfaces of new and
expiring webs of tubular material,
a first outer sheet adapted to overlie and sterilize an outer surface of a new web
substantially opposite said inner sheet,
a second outer sheet adapted to overlie and sterilize an outer surface of an expiring
web substantially opposite said inner sheet, and
means carried by one of said outer sheets for forming an opening through walls of
new and expiring webs withwhich said package is engaged to allow the sterile transfer
of a filling nozzle from the expiring to the new web of tubular material.
[0008] From another aspect, the invention provides a method of maintaining the sterility
of a tubular web of bags having sterile interiors while transferring a filling nozzle
from a tube of material having a sterile interior to said tubular web of bags, characterised
by the steps of:
positioning a first sterilant in contact with an outer surface of said tubularweb
of bags,
positioning a second sterilant between and in contact with opposing inner surfaces
of said tubular web of bags and said tube of material opposite said first sterilant,
positioning a third sterilant in contact with an outer surface of said tube of material
opposite said first sterilant,
piercing walls of said tubular web of bags and said tube of material in areas thereof
contacted by said sterilants to form openings through said walls, and
passing said filling nozzle from said tube of material to said tubular web of bags
through said openings in said walls thereof.
[0009] More specifically, in accordance with one embodiment of the present invention, a
package is provided which is of book-like form having three leaves or sheets. The
outer sheets may be formed of a single sheet having one surface covered with a pressure-sensitive
adhesive and folded in half so that its adhesive covered surface faces inwardly. Of
course, the outer sheets can also be formed as two separate sheets of material each
having an inner surface covered with a pressure-sensitive adhesive.
[0010] Mounted on the adhesive covered surface of each of the outer sheets is an anvil plate
formed of a relatively harder material, such as a tough nylon or a high density polyethylene,
and covered with a layer of absorbent material. Cover sheets cover both the layers
of absorbent material and the pressure-sensitive, adhesive coated surfaces of-the
outside sheets to prevent them from sticking together.
[0011] The center sheet or leaf of the package is comprised basically of a layer of absorbent
material bordered on at least three sides by a double-faced, pressure-sensitive adhesive
tape or similar material, which has both of its adhesive surfaces covered by cover
sheets to prevent adhesion to the outer sheets.
[0012] A curved knife is included in the package adhered to one of the anvil plates by a
strip of double faced pressure sensitive tape and covered by a layer of absorbant
material that covers that anvil plate. Of course, the knife may be reusable and inserted
in the appropriate place in the package just prior to use or it may be of relatively
inexpensive construction so that each package comes equipped with a disposable knife.
[0013] In use the cover sheet is peeled off the inner surface of a first one of the outer
sheets, exposing the absorbant layer overlying the anvil plate adhered to that outer
sheet, and a sterilizing agent such as hydrogen peroxide is applied to the absorbant
layer. The exposed, adhesive coated inner surface of the outer sheet with the absorbant
layer carrying the sterilizing agent is then applied to an outer surface of the leading
end of a new web of bags adjacent its upper corner.
[0014] To facilitate this operation the outer surface of the first one of the outer sheet
may be provided with a strip of double-faced, pressure-sensitive adhesive tape which
permits the package to first be adhered to a work plate mounted in a convenient position
along the filling line and then the leading end of the new web applied to the inner
surface of that outer sheet.
[0015] Next the cover sheets on the adhesive covered tape forming a frame around the middle
absorbant layer of material on the side facing the leading end of the new web are
removed and a sterilizing medium is applied to the absorbant material. The adhesive
tape forming the frame for the middle absorbant layer is then adhered to the surface
(hereinafter referred to as the "inner surface") of the leading end of the new web
of bags opposite the surface to which the outer sheet had previously been applied.
[0016] Next the cover sheets on the opposite side of the frame around the middle absorbant
layer are removed and a surface (hereinafter referred to as the "inner surface") of
the trailing end of the expiring web of bags is pressed into engagement with it at
a point on the trailing end of the expiring web of bags adjacent its upper corner.
Following this the cover sheet is removed from the second outer sheet and the absorbant
layer carried by this second outer sheet is supplied with a sterilizing material such
as hydrogen peroxide.
[0017] If the package does not have a blade installed, prior to applying the sterilizing
material to the absorbant layer the absorbant material is lifted slightly from the
adhesive covered surface of the outer cover sheet to permit the curved blade to be
inserted between the absorbant layer and the anvil plate carried by the cover sheet.
With a knife blade in place and the absorbant layer overlying the knife blade carrying
a sterilizing agent, the second outer sheet is folded over the top of the trailing
end of the expiring web and adhered to the outer surface of that web.
[0018] Next, the entire assembly, that is, the two webs of packaging material and the three
sheets of the package together with the associated anvil plates, sheets of absorbant
material and knife are clamped in any convenient type of clamping device, causing
the knife to pierce first through the absorbant layer of material overlying the knife,
then through the outer surface of the trailing end of the expiring web, then through
the inner surface of the trailing end of the expiring web, next through the central
absorbant layer of the package, then through the inner surface of the leading end
of the new web of bags, next through the outer surface of the leading end of the new
web of bags and finally, through the absorbant layer of material overlying the anvil
on the first outside sheet of the package.
[0019] When this operation has been accomplished the smooth, tapered end of the filling
nozzle will pass readily through the aligned incisions formed in the opposed inner
surfaces of the leading and trailing ends of the new and expiring webs of bags, respectively.
The outer sheet and anvil plate of the package overlying the outer surface of the
leading end of the new web of bags prevents the nozzle from passing through the cut
formed through the outer surface of the leading end of the new web of bags.
[0020] It should also be noted that preferably the apex of the curved knife should be placed
as nearly as possible coincident with the downstream edge of the transverse seal closing
the end of the expiring web of bags. This greatly facilitates passage of the nozzle
from the expiring web into the new web by preventing the formation of a pocket at
the end of the expiring web in which the nozzle end might become engaged if the incision
through the inner surface of the trailing end of the expiring web was spaced downstream
from the edge of the transverse seal at the end of the expiring web.
[0021] The above description is specific with respect to the transfer from an expiring web
to a new web. The same general conditions apply where the transfer is from a sterilizing
boot at start-up to the initial web of bags. The only difference being that instead
of the package being applied to a trailing end of an expiring web of bags it is applied
to the upstream end of a sterilizing boot.
[0022] In order that the invention may be more readily understood, reference will now be
made to the accompanying drawings, in which:- a
Fig. 1 is an overall view of part of/packaging line employing a splicing operation
utilising a package or kit in accordance with one embodiment of the present invention;
Fig. 2 is an enlarged view taken on line 2--2 of Fig. 1, illustrating the clamping
station;
Fig..3 is an enlarged view of a portion of Fig. 1;
Fig. 4 is an end view of the package showing the three leaves or sheets thereof in
an expanded position;
Fig. 5 is a side view of an outer sheet of the package with the other portions or
members of the kit removed;
Fig. 6 is a cross sectional view taken on line 6--6 of Fig. 5;
Fig. 7 is a side view of the inner sheet of absorbent material of the package embodying
the present invention with the other portions or members removed;
Fig. 8 is a cross sectional view taken along line 8--8 of Fig. 7;
Fig. 9 is a side view of a second outer sheet of the package with the other portions
of the package removed;
Fig. 10 is a cross sectional view taken along line 10--10 of Fig. 9;
Fig. 11 is a cross sectional view through a splice made between the trailing end of
an expiring web and the leading end of a new web as the filling nozzle penetrates
into the new web; and
Fig. 12 is a perspective view of a knife blade for use in the package embodying the
present invention.
[0023] Fig. 1 of the drawings shows a kit or package 10 embodying the present invention
as it would be applied to the trailing end of an expiring web 12 of tubular material
and the leading end of a new web 14 of tubular material. The webs 12 and 14 can be
of the type described in the above noted U.S. Patent No. 4,021,283, and are formed
of flattened tubes of low density polyethylene or the like having transverse seals
16 which extend from their lower edges to a point short of their upper edges to form
a continuous channel along the upper edge of the web to receive a filling nozzle 18.
Each of the webs 12 and 14 are formed with sterile interiors and to preserve the sterility
the trailing edge of the web 12 is sealed, as at 20, and the leading edge of the web
14 is sealed, as at 22.
[0024] Turning next to Fig. 4 of the drawings, it will be seen that the package 10 includes
an inner sheet 24 and outer sheets 26 and 28, respectively. Outer sheets 26 and 28
can be formed as, and in fact are shown as, a single sheet of paper or similar material
folded in half, although it will be apparent that they could be separate sheets attached
to each other and the upper end of sheet 24 to provide the book-like configuration
shown in Fig. 4 of the drawings.
[0025] Considering Figs. 4, 7 and 8 together, it will be seen that the -inner sheet 24 includes
a layer 30 of absorbant material which may, for example, be an absorbant paper material
such as paper toweling or blotter paper. Layer 30 is framed on three sides by strips
of double faced pressure sensitive adhesive tape 32 which is covered by cover strips
34 and 35.
[0026] The inside surface of the first outer sheet 26, as seen in Figs. 4, 5 and 6 of the
drawings, is covered with a pressure sensitive adhesive and has adhered to its face
a pad 36 of absorbant material similar to the material 30. Interposed between a portion
of the pad 36 and the sheet 26 is an anvil plate 38 made of material much harder than
the materials from which the webs 12 and 14 of bags and the layers 24, 26 and 28 are
made. A cover sheet 40 overlies the entire face of the sheet 26, and attached to an
outer surface of the cover sheet 40 is a strip 42 of double faced pressure sensitive
adhesive tape covered by a cover strip 44.
[0027] Figs. 4, 9 and 10 show the second outer sheet 28. Sheet 28, similarly to sheet 26,
has its inner face covered with a pressure sensitive adhesive. Adhered to the inner
face of the sheet 28 is an anvil plate 48 which, similarly to anvil plate 38, is formed
of a material substantially harder than that of either of the webs 14 or the sheets
24, 26 and 28. A strip of double faced pressure sensitive tape 50 is adhered to one
face of the anvil plate 48 and a curved knife 52 is adhered to the tape 50. Overlying
the knife 5
2 is a layer of absorbant material 54, which may be of the same material as layers
30 and 36. A cover sheet 56 then covers the entire assembly.
[0028] Knife 52, as can be best seen in Fig. 12, is of substantially triangular cross sectional
configuration and includes a cutting edge 57 and an opposite, substantially flat edge
58. It is the flat edge 58 that is adhered to the face of the strip 50.
[0029] In use the cover strip 44 is peeled from the outer face of the strip of double faced
pressure sensitive adhesive tape 42 and the package is stuck to a stationary plate
60 which, as seen in Fig. 1, is mounted at a convenient position adjacent the end
of the filling nozzle 18. Next the leading end of the new web of bags 14 is brought
into position and the cover sheet 40 is removed from the first outer sheet and the
upper leading end, the upper left hand corner as seen in Fig. 3 of the drawings, of
the web 14 is applied to the adhesive covered surfaces of the sheet 26. Prior to this
the layer 36 is treated with a sterilizing agent such as hydrogen peroxide so that
the sheet acts as a sterilant in contact with an outer surface of the new web.
[0030] Next the cover strips 35 are removed from the inner sheet 30 and this sheet is adhered
to the inner face of the new web 14. Again, the absorbant layer 30 has a sterilizing
agent applied to it so that this sheet then acts as a sterilant in contact with the
inner face of the new web 14 and, as will be seen presently, in contact with the opposing
inner face of the expiring web 12. After the inner sheet is adhered to the inner face
of the new-web 14, the cover strips 34 are removed and the trailing end of the expiring
web 12 is brought into position and adhered around the opposite face of the inner
sheet 30.
[0031] Next, the cover sheet 56 is removed from the second outer sheet 28 and the layer
54 has applied to it a sterilizing agent so that when the sheet 28 is adhered to the
outer face of the expiring web 12 it acts as a sterilant, sterilizing the area within
which it is in contact. It will also be noted that the package is positioned with
respect to the trailing end of the expiring web 12 such that the apex of the knife
52 is coincident with the transverse seal 20 which seals the end of the expiring web
of bags 12.
[0032] With the package thus engaged with the leading and trailing ends of the new and expiring
webs, respectively, the entire assembly is moved to the clamping station 61, which
may be of any convenient form, but which is shown in Fig. 2 as including a stationery
plate 62, a movable plate 64 hinged to the plate 62 at 66, a handle 68 and a mounting
bracket 70.
[0033] With the assembly at the clamping station 61 the handle 68 is moved downwardly in
a direction indicated by the arrow in Fig. 2 of the drawings forcing the knife 52
through the absorbant layer 54, the outer wall of the expiring web 12, the inner wall
of expiring web 12, the sterilant 30, the inner wall of the new web 14, the outer
web of the new wall 14, and the absorbant layer 36.
[0034] This forms an opening through the walls of the new and expiring webs, permitting
the nozzle 18, as seen in Fig. 11 of the drawings, to pass from the expiring web 12
into the new web 14. Because all areas of the tubes through which the openings are
formed by the knife 52 are in contact with sterilants there is no danger of contamination
of the system and the sterility of the interior of both the new and old webs 12 and
14 is maintained during transfer of the nozzle.
[0035] To facilitate this transfer the nozzle 18 may be provided with an air line 72 which
permits a blast of sterile air to be ejected from the leading end of the nozzle to
spread apart the edges of the cuts formed through the inner walls of the new and expiring
webs.
[0036] Thus, the present invention provides a package for maintaining the sterility of the
interiors of sterile tubes of packaging material as a sterile filling nozzle is transferred
from an expiring web of bags into a new web of bags and a process for using it.
[0037] While the method and apparatus herein described constitute preferred embodiments
of the invention, it is to be understood that the invention is not limited to this
precise method and form of apparatus, and that changes may be made in either . without
departing from the scope of the invention as defined in the appended claims.
1. A package (10) for maintaining the sterility of new and expiring webs (14, 12 respectively)
of tubular material having sterile interiors while transferring a filling nozzle (18)
from said expiring to said new web, characterised by:
an inner sheet (24) adapted to contact and sterilize opposed inner surfaces of new
and expiring webs of tubular material,
a first outer sheet (26) adapted to overlie and sterilize an outer surface of a new
web (14) substantially opposite said inner sheet (24),
a second outer sheet (28) adapted to overlie and sterilize an outer surface of an
expiring web (12) substantially opposite said inner sheet (24), and
means (52) carried by one of said outer sheets for forming an opening through walls
of new and expiring webs with which said package is engaged to allow the sterile transfer
of a filling nozzle (18) from the expiring to the new web of tubular material.
as 2. A package/claimed in claim 1, including means (38,48) carried by said outer
sheets (26,28) for preventing the formation of an opening therethrough by said opening
forming means (52).
. as 3. A package/claimed in claim 2, wherein said means (38,48) carried by said outer
sheets for preventing the formation of an opening therethrough comprise anvil plates
of substantially greater hardness than the material of which said inner sheet (24)
and outer sheets (26,28) are formed.
as 4. A package/claimed in any preceding claim, wherein said sheets (24, 26, 28) each
include a layer (30, 36, 54 respectively) of absorbent material.
as 5. A package/claimed in any preceding claim, wherein adhesive said sheets include
pressure sensitive/coated surfaces.
as 6. A package/claimed in any preceding claim, wherein:
each of said sheets (24, 26, 28) includes a layer of absorbent material (30, 36, 54
respectively) for receiving a liquid sterilizing agent, and a pressure sensitive adhesive
coated surface for adhering to said surfaces of said webs (12, 14),
said outer sheets (26, 28) carry anvil plates (38, 48) of substantially greater hardness
than the material of which said inner sheet (24) and outer sheets (26, 28) are formed
for preventing the formation of an opening therethrough by said opening forming means,
and
said opening forming means (52) comprises a curved knife carried by said second outer
sheet (28).
7. A method of maintaining the sterility of a tubular web (14) of bags having sterile
interiors while transferring a filling nozzle (18) from a tube of material (12) having
a sterile interior to said tubular web (14) of bags, characterised by the steps of:
positioning a first sterilant (36) in contact with an outer surface of said tubular
web (14) of bags,
positioning a second sterilant (30) between and in contact with opposing inner surfaces
of said tubular web (14) of bags and said tube (12) of material opposite said first
sterilant (36),
positioning a third sterilant (54) in contact with an outer surface of said tube (12)
of material opposite said first sterilant (36),
piercing walls of said tubular web of bags and said tube of material in areas thereof
contacted by said sterilants to form openings through said walls, and
passing said filling nozzle (18) from said tube of material to said tubular web of
bags through said openings in said walls thereof.
8. The method claimed in claim 7, wherein said step of positioning sterilants (36,
30, 54) comprises positioning sheets of material carrying a sterilizing agent.
9. The method claimed in claim 7 or 8, wherein said positioning of said sterilants
includes adhering said sterilants (36, 30, 54) to said surfaces.
10. The method claimed in claim 7, 8 or 9, wherein said step of piercing said walls
comprises pressing a curved knife (52) through said walls and said sterilants (36,
30, 54) between plates (38, 48) carried by said first and third sterilants (36, 54
respectively).